OPERATION REVIEW - 02

STPP 2x600MW

r 2015

11/06/2020 August-2017 1
OR#1
 INDEX
S.No. Particulars

1 Highlights

2 Station Performance

3 Station Performance Analysis

4 Chemistry

5 Coal handling Plant

6 Statutory /Regulatory Updates

10 OR#1 2
 Highlights and Lowlights

 Highlights

• Unit#1-100% Availability for the month.

• Highest Station PLF for the Month -98.43% since inception. Earlier best was 95.15%
in the month of Feb,17.

• Highest Station generation in the month since inception  -878.81 MU. Earlier best was
776.5MU in the Month of March,2017.

• Highest Availability Factor  ( Running Hour) in the month since inception 99.54%.
Previous best was 98.9% in the month of March,17

• Station Auxiliary Power consumed   5.82% in the month of August,2017  lowest since
inception. Previous best was 6.2% in the month of  July,2017.

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 Highlights and Lowlights

 Highlights

• Lowest Specific Oil consumption for the month -  0.09 ml/kwh, previous best achieved
0.44 ml/kwh  in the month of June,2017.

• Lowest Station  DM water (cycle) consumption for the month 0.72%, previous best
achieved  0.82% in the month of May,2017

• Lowest specific oil consumption in any unit -0.01ml/kwh of Unit#1 in the month since
inception. Earlier best was 0.18 ml/Kwh by Unit#1 in April,17

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 2. STATION PERFORMANCE

DC-SG-AG % (Station)
110.0

100.0

90.0

80.0

70.0
Axis Title
60.0

50.0

40.0

30.0

20.0
July,17 Aug,17 Target Sep,17 FY 2017-18

11/06/2020 OR#1 5
 2. STATION PERFORMANCE

PLF-%- U1/U2/Station
120.0

100.0

80.0

Axis Title 60.0

40.0

20.0

0.0
July,17 Aug,17 Target Sep,17 FY 2017-18

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 2. STATION PERFORMANCE

Availability Factor %
120

100

80

Axis Title 60

40

20

0
July,17 Aug,17 Target Sep,17 FY 2017-18

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 2. STATION PERFORMANCE

APC-%
7

6.5

5.5

Axis Title 5

4.5

3.5

3
July,17 Aug,17 Target Sep,17 FY 2017-18

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 2. STATION PERFORMANCE

Specific Oil Consumption-mL/kWh

0.7

0.6

0.5

0.4
Axis Title
0.3

0.2

0.1

0
July,17 Aug,17 Target Sep,17 FY 2017-18

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 2. STATION PERFORMANCE

DM Cycle Make Up %
1.4

1.2

0.8

Axis Title
0.6

0.4

0.2

0
July,17 Aug,17 Target Sep,17 FY 2017-18

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 2. STATION PERFORMANCE
STATION
PERFORMANCE INDICES UNIT – 1 UNIT – 2
(2X600MW)
Generation (MU)
Actual for the Month 443.08 435.73 878.81
432.02 448.54 776.49
Previous Best
Apr’ 17 May’ 17 Mar’17
YTD 1810.26 1992.15 3802.41

STATION
PERFORMANCE INDICES UNIT – 1 UNIT – 2
2X600MW
PLF (%)      
Actual for the Month 99.26 97.61 98.43
100 100.11 95.1
Previous Best
Apr’ 17 Feb’ 17 Feb’ 17
YTD 82.17 90.42 86.29
Deemed PLF For the Month 100.53 99.29 99.91
100 100.2 97.9
Previous Best(Deemed)
Apr’ 16 Feb’ 17 Mar’17
Deemed PLF-YTD 87.18

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 2. STATION PERFORMANCE
AUX POWER CONSUMPTION (%)

STATION
PERFORMANCE INDICES UNIT – 1 UNIT – 2
(2X600MW)

APC (%)

Actual for the Month 5.69 5.95 5.82

5.97 5.59 6.2

Previous Best
Jan’ 17 May’ 17 July’ 17

YTD 6.28 6.33 6.31

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 2. STATION PERFORMANCE
STATION
PERFORMANCE INDICES UNIT – 1 UNIT – 2
(2X600MW)

SCC (gms/kwh)

SCC 559 551 555

Design @ 4529 GCV 486 486 486

YTD 566 561 564

Coal Consumption (MT)*

Monthly (MT) 247616 240110 487726

Yearly (MT) 1025000 1118478 2143478

* Subject to Physical verification

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 2. STATION PERFORMANCE
SPECIFIC OIL CONSUMPTION

STATION
PERFORMANCE INDICES UNIT – 1 UNIT – 2
(2X600MW)
SOC (ml/kwh)      
Actual for the Month 0.01 0.18 0.09

0.18 0.20 0.44

Previous Best
Apr’ 17 Feb’ 17 June’ 17

YTD 0.43 0.41 0.42

Oil Consumption (KL)

Monthly 5.88 77.13 83.01

YTD 784.66 821.18 1605.83

11/06/2020 OR#1 14
 2. STATION PERFORMANCE
DM WATER
STATION
PERFORMANCE INDICES UNIT – 1 UNIT – 2
(2X600MW)

DM MAKE UP (%)      

Actual for the Month 0.69 0.76 0.72

0.60 0.86 0.90

Previous Best
Mar’ 17 June’ 17 Mar’ 17

YTD (After COD) 0.43 1.00 0.88

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 3. STATION PERFORMANCE ANALYSIS
OUTAGE STATISTICS – (NO. OF SHUTDOWN)

Station
Performance Indices Unit-1 Unit-2 (2X600 MW)

During Month
a) Planned 0 0

Tripping 0 03
03
b) Forced BTL 0 0

Withdrawl

During Financial Year

a) Planned 0 0

b) Forced YTD 09 15 24

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 3. STATION PERFORMANCE ANALYSIS

TRIPPING & WITHDRAWL DETAILS FOR THE MONTH

Tripping Synchronization
Outage
Gen Loss
Unit duration Reason of Tripping
Date Time Date Time (MU)
(hr)
Both FD Fans off 3.3
1 01.08.17 01:59 01.08.17 03:45 01:46 1.62
KV Bus 2CA got dead
Both FD Fans off 3.3
1 01.08.17 16:05 01.08.17 19:28 03:23 3.1
KV Bus 2CA got dead
Furnace Pressure
1 04.08.17 04:24 04.08.17 06:04 01:40 0.9
High
Total Outage(6.81 Hrs) 06:49 5.62

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OR#1
 3. STATION PERFORMANCE ANALYSIS

Action Plan for Availability

Unit Observation Action Plan Target

3.3KV 2CA Sec-A Mill G
breaker shutter lifting
2 3.3 KV Bus Got Dead mechanism bolt was Attended
found in open condition.

2CA I/C-1 upstream control cable

connected to UAT-2B incomer
Cross connection of
(HT) and incomer-2 Breaker
control cable to be During SD
upstream control cable
corrected .
connected to UAT-2A incomer
2
breaker(HT)
Relay setting of HT side
relay to be done.
HT side relay setting During SD
Approval awaited from
BHEL
Availability of Clinker
2 AHP-Clinker grinder availability In process
Grinder to be ensure.

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 3. STATION PERFORMANCE ANALYSIS
Generation Loss % For The Month Aug,2017

Electrical; 4.72; 0.53% AHP; 0.9; 0.10% Grid Restriction; 13.17; 1.47%

Gen
Electrical
AHP
Grid Restriction

Gen
878.81
97.91%

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 3. STATION PERFORMANCE ANALYSIS

Availability Loss % For The Month Aug,2017

Electrical
AHP
1.67
5.15
0.69%
0.22%

Availability
Electrical
AHP

Availability
737.18
99.08%

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 3. STATION PERFORMANCE ANALYSIS
Area wise % of Availability loss during Financial Year 2017-18

AREA WISE OUTAGE SUMMARY

AREA NOS HOURS MU %
BTL 9 813.32 487.99 11.07
Electrical 5 62.70 37.618 0.85
C&I 4 9.50 5.7 0.13
Operation 5 10.35 6.21 0.14
AHP 1 1.66 1 0.02
Total 24 897.50 538.5 12.20

AREA WISE OUTAGE SUMMARY

  Unit-I Unit-II
AREA NOS HOURS MU % NOS HOURS MU %
BTL 5 576 345.6 15.7 4 237.4 142.4 6.5
Electrical 1 5 2.8 0.1 4 58.0 34.8 1.6
C&I 2 7 4.0 0.2 2 2.8 1.7 0.1
Operation 1 1 0.5 0.02 4 11.1 6.7 0.3
AHP         1 1.7 1.0 0.0
Total 9 588.3 353 16.0 15 310.9 186.5 8.5

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 3. STATION PERFORMANCE ANALYSIS
Area wise % of Availability loss during Financial Year 2017-18

Electrical &AHP
COperation
I
62.7 9.5 1.66
10.35
6.99% 0.18%
1.15%
1.06%

BTL
Electrical
C&I
Operation
AHP

BTL
813.32
90.62%

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 3. STATION PERFORMANCE ANALYSIS
GENERATION VARIANCE

Generation Loss (MU) Details

  U#1 U#2 Station

Rated Generation 446.40 446.40 892.8

Actual Generation 443.08 435.73 878.81

Generation Loss 3.32 10.67 13.99

CATEGORY TYPE CAUSE U#1 U#2 Station

Planned 0 0 0
Outage
Forced   0 5.62 5.62

Partial Grid Grid Restriction 5.67 7.5 13.17

Loading Equipment Problem.
0.08 0.3 0.38

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 2. STATION PERFORMANCE
UNBURNT CARBON IN ASH

Unit-1 Unit-2
ITEM LIMIT
Max Min Avg Max Min Avg

Bottom Ash 2.50 2.00 2.29 2.66 2.10 2.33

< 2.5%
Fly Ash 0.52 0.18 0.31 0.56 0.20 0.33
< 1%

11/06/2020 OR#1 24
 3. STATION PERFORMANCE ANALYSIS
U#1 APH PERFORMANCE FOR THE MONTH OF AUG
ONLINE OFFLINE
SI.No. Parameter Unit Design
APH-A APH-B APH-A APH-B
1 FG I/L temperature °C 335 345 351 332 345
2 FG O/L temperature °C 138 143 130 142 129
3 APH FG I/L O2 % 3.53 3.74 3.67 3.81 4.07
4 APH FG O/L O2 % 5.03 5.63 4.90 5.33 5.66
5 APH Leakage % 9 12.27 7.68 9.70 10.37
6 Corrected FG O/L temp °C 150 158 139 154 141

U#2 APH PERFORMANCE FOR THE MONTH OF AUG

ONLINE OFFLINE
S.No. Parameter Unit Design
APH-A APH-B APH-A APH-B
1 FG I/L temperature °C 335 359 361 352 351
2 FG O/L temperature °C 138 131 131 131 132
3 APH FG I/L O2 % 3.53 4.06 3.42 3.90 3.71
4 APH FG O/L O2 % 5.03 6.55 5.3 5.96 6.08
5 APH Leakage % 9 17.19 11.97 13.70 15.88
6 Corrected FG O/L temp °C 150 151 144 147 151
11/06/2020 OR#1 25
 3. STATION PERFORMANCE ANALYSIS
HEAT RATE & DEVIATIONS - U#1
Actual Heat rate
deviation
PARAMETER Rated Expected (avg (Kcal/kwh Reasons
values) )
Unit Load (MW) 600 600.0 594.4 2.3  
Main Steam Pressure (Ksc) 174.41 174.41 171.0 4.6 Within limit
Main Steam temp(0C) 537 537.0 533.6 1.9
 
RH Steam Temp(0C) 565 565.0 559.9 2.6
Part load operation, High
RH Spray(TPH) 0 0.0 7.1 1.3 Excess Oxygen in view of
Clinkering tendancy
Due to Condensor tube fouling.
Low effectivness of Cooling
Cond Vacuum (Kg/cm2) 0.1081 0.1081 0.18 66.0 tower, CW quality not as per
standarad
DM cycle make up (%) 2 0 0.7 17.6* Within limit
Feed Water Temp 278 278.0 281.6 -3.0  
BOILER          
Excess air (O2) 3.53 3.5 3.7 1.6  
Exit Flue Gas Temp 138 138.0 135.0 -3.6  
Unburned Carbon 3.62 3.6 2.6 -3.0  
Coal Moisture 7.29 7.3 10.7 6.9  
Total ( Heat Rate Deviation)   - - 95.1  

* Calculated based on loss method of Turbine.

11/06/2020 OR#1 26
 3. STATION PERFORMANCE ANALYSIS
HEAT RATE & DEVIATIONS - U#2
Actual Heat rate
PARAMETER Rated Expected (avg deviation Reasons
(Kcal/kw
values) h)
Unit Load (MW) 600 600.0 596.7 1.3  
Main Steam Pressure (Ksc) 174.41 174.41 169.1 6.4  
Main Steam temp(0C) 537 537.0 532.5 2.4  
RH Steam Temp(0C) 565 565.0 563.8 0.6 Load variation.
Part load operation, High Excess
RH Spray 0 0.0 15 2.6 Oxygen in view of Clinkering
tendancy
Due to Condensor tube fouling.
Low effectivness of Cooling
Cond Vacuum (ata) 0.1047 0.1047 0.165 56.0
tower, CW quality not as per
standarad
DM cycle make up (%) 2 0 0.8 14.1 Within limit
Feed Water Temp 278 278.0 280.0 -1.7  
BOILER          
Excess air (O2) 3.53 3.5 4.0 3.8  
Exit Flue Gas Temp 138 138.0 133.6 -5.3  
Unburned Carbon 3.62 3.6 2.7 -2.8  
Coal Moisture 7.29 7.3 10.9 7.3  
Total   -   84.8  
* Calculated based on loss method of Turbine.
11/06/2020 OR#1 27
 3. STATION PERFORMANCE ANALYSIS
GENERATOR OPERATING PARAMETER
PARAMETERS Description Limit Max/Min U-1 U-2
Min 97% 97%
Purity(online) ≥98 %
Max 98% 98%
-25°C Min -9.7 -9.9
Dew Point
-5°C Max -9.7 -9.9
Hydrogen Parameters

Hot Gas temp ≤ 68°C Max 82°C 75°C

Cold Gas Temp ≤ 48°C Max 56°C 52°C

Stator Water Winding Outlet < 73 °C Max 72°C 68°C
Parameters Temp
Max 53.4°C 48°C
Winding inlet Temp 40 °C to 50 °C
Min 50°C 46°C
Conductivity <2.0 μs/cm Max 1.01 1.2

11/06/2020
OR#1 28
 3. STATION PERFORMANCE ANALYSIS
GENERATOR OPERATING PARAMETER

PARAMETERS Description Limit Max/Min U-1 U-2

Conductivity 0.5-1.5 μs/cm Max 1.01 1.2
Stator Water
Parameters Min 8.56 8.76
pH 8.5 to 9.0
Max 8.56 8.76
<20 ppb
Min
<20 <20
DO
<20 ppb Max
<20 <20

Min 78°C 54°C

Core Temp <120 °C
Max 102°C 82°C
Stator Core & Slot
temperatures Min 68°C 68°C
Slot Temp <120 °C
Max 72°C 72°C

11/06/2020
OR#1 29
 3. STATION PERFORMANCE ANALYSIS
GENERATOR OPERATING PARAMETER

PARAMETERS Description Limit U-1 U-2

H2 Consumption Filling / Purging 2 per day/unit 45 89*

( No of Cylinder)

H2 dryers in service A or B or Both A+B A+B

Both are Both are

H2 dryers Availability A/B available available

CO2 consumed NIL NIL

CO2 Cylinders in stock 30 per unit 30 13**

*Leakage identified from Dew point sensor and attended,

**17 CO2 cylinders are pending from STPP.

11/06/2020
OR#1 30
 3. STATION PERFORMANCE ANALYSIS
CT PERFORMANCE FOR THE MONTH

Unit-1 Unit-1 Unit-2 Unit-2

PARAMETERS DESIGN
1-A 1-B 2-A 2-B

RANGE 10.5 8.26 9.16 12.24 10.48

APPROACH 4.3 11.76 11.97 9.62 10.24

EFFECTIVENESS 70.9 41.24 43.33 55.99 50.58

COC FOR THE MONTH

PARAMETERS DESIGN

Average 4.49

COC Max 5.0 5.0

Min 4.1

11/06/2020 OR#1 31
 3. STATION PERFORMANCE ANALYSIS
ESP PERFORMANCE & STATUS

Unit-1 Unit-2

Average Fields in service 70/72 67/72

EERM – 72/72 EERM – 72/72

Availability of Rapping CERM – 71/72 CERM – 71/72
Motors
GDRM-8/8 GDRM-8/8

Availability of Ash level 72 72

indicators

11/06/2020 OR#1 32
 3. STATION PERFORMANCE ANALYSIS
SOOT BLOWERS AVAILABILITY

Unit-1 Unit-2

Frequency Non Availability Non Availability

6 Nos defective out of 88 Nos

Water Wall Soot 6Nos defective out of 88
Twice in a day
blowers Nos

8 Nos defective out of 42 8 Nos defective out of 42 Nos

LRSB Twice in a week
Nos

APH Soot Available Available

Once in a Shift
blowers

11/06/2020 OR#1 33
 3. STATION PERFORMANCE ANALYSIS
Auto Loops Status
 Description Reason for not
UNIT-1 Reason for not in UNIT-2 in Auto
Auto

FD Fan Controller Auto Auto

PA Fan controller Manual Hdr. Pr. fluctuation Manual Hdr. Pr. fluctuation

Furnace Pressure Controller Auto Auto

O2 Controller Auto Auto

No clearance from
Feeder Controller Auto Manual
BHEL

Mill Cold PA controller Auto Manual Fine Tuning Required

Mill hot PA controller Auto Manual Fine Tuning Required

 3. STATION PERFORMANCE ANALYSIS
Auto loops status
Reason for
Reason for not
Description UNIT-1 not in Auto UNIT-2 in Auto
Hot well level Controller Auto Auto
D/A Level Controller Auto Auto
Drum level Controller Auto Auto
D/A Pegging steam control Auto Auto
SH Spray Controller (L/R) Auto Auto
Auto Tuning
RH Spray Controller (L/R) Auto Manual
Required

Coordinated Master control Auto Manual No clearance from

BHEL
Turbine drains controller Auto Auto
Auto Tuning
Mill outlet temp. controller Auto Manual Required
Operation Operation
Burner tilt controller Manual Manual
requirement requirement

11/06/2020 35
 3. STATION PERFORMANCE ANALYSIS
Auto loops status
Reason
Reason for
Description UNIT-1 for not in UNIT-2
Auto not in Auto

HFO/LDO pr. controller Auto Auto

Atomizing steam pr. controller Auto Auto

SADC Controller Auto Auto

Boiler Master Auto Manual No clearance

from BHEL
GSC Min. R/C controller Auto Auto

BFP recirculation controller Auto Auto

MOV spare not

Turbine lube oil temp. controller Auto Manual available

Seal steam pr controller Auto Auto

TDBFP lube oil temp. controller Auto Auto

11/06/2020 36
 3. STATION PERFORMANCE ANALYSIS
Auto loops status
Reason
for Reason for
Description UNIT-1 UNIT-2
not in not in Auto
Auto
Primary water temp controller Auto Auto

Over Head(ECW) tank level controller Auto Auto

MOV spares
Gen Cold Gas Temp controller Auto Manual not available
HP BY pass Auto Auto

HP BY pass Temp Controller Auto Auto

LP By pass Auto Auto

LP By pass Temp Controller Auto Auto

MOV spares
HPCF Temp control Man not available Auto

11/06/2020 37
 3. STATION PERFORMANCE ANALYSIS
CRITICAL PROTECTION CHECKS

UNITS PROTECTIONS DATE OF LAST TESTING

Boiler- MFT 25/07/2017

Turbine- TP 25/07/2017

UNIT-1 Turbine- Over Speed (Oil injection test) 20.02.2017

Turbine ATT

Generator 13.03.2016

Boiler- MFT 30/07/2017

Turbine- TP 30/07/2017

UNIT-2
Turbine- Over Speed (Oil injection test) 28/01/2017

Turbine ATT

Generator 28.05.2016

11/06/2020 OR#1 38
 3.STATION PERFORMANCE ANALYSIS
SWITCHYARD EQUIPMENT AVAILABILITY:
S.No. Description SWYD (bays)
1 Primary Equipments All 14 bays are in service.
2 Protection Panels All are in healthy condition

3 OPGW Panels Panel is working properly

4 SCADA System Both server & DR system is working properly

11/06/2020 OR#1 39
 STATION PERFORMANCE ANALYSIS
BATTERY BANK STATUS

Sp. Electrolyt
Equipment Nos Volts(DC) Gravity e Level Remarks

• Total cells 340 cells available in each Section A & B.

U#1 Battery Two 220  1220 Normal • In section –B battery number 206,240,262, 234,287,340
banks and also section-A battery number 6,213,&329 found
leakage .

• Total cells 340 cells available in each Section A & B

• At battery section-A , battery number 256 cell is not
available & in battery 201,207,234,320 are found
U#2 Battery Two 220 1220  Normal leakage and in section –B ,battery number
banks 254,255,256,257 not available and are found leakage .

Normal • in leakage condition at Unit-2 .

Unit#01 &02 All are in healthy condition except one number 79 & 6 is
Ups battery One 340V 1220

 Normal •
CHP Battery Battery Charger –A&B both are in service condition and
Two 220  1220
Bank healthy condition.

11/06/2020 OR#1
 STATION PERFORMANCE ANALYSIS
BATTERY BANK STATUS
Volts Sp. Electrolyt
Equipment Nos (DC) Gravity e Level Remarks

 Normal •
AHP Battery Battery Charger –A&B both are in service
Two 220
Bank  1220 condition and healthy condition

48
SWYD Banks  One Dry cell  N/A • All Battery are in healthy condition.

 Normal • battery bank B are in by pass condition

5 number in battery bank A & 2 numbers in
Two 220 1220
SWYD Banks
 Normal •
48 V Battery charger-2 has not
Two 48 1220
commissioned

 Normal • healthy condition

All 4 numbers of battery in each set are in
DG Set Three  24  1230

Diesel Fire
Hydrant  One  24  1230  Normal • Battery Charger is in service condition
Pump

Diesel Fire
Spray Pump One 24  1220  N/A • Yet To be commissioned

11/06/2020 OR#1
 3. STATION PERFORMANCE ANALYSIS
PLC AVALABILITY

LOCATION STATUS REMARK

Make-up water ,PT Plant, Chlorination and
DMP in service Service water are under commissioning.
DMP
CSSP -- Erection Pending

Under Service Local PLC, Stacker/ Reclaimer, Track Hopper

CHP and concern belt ways under commissioning

Local PLC, Ash Water Recovery System,

AHP Under Service HCSD, SILO & Ash water Pump House are
under commissioning

H2 Plant Erection under progress Erection under progress

Comp House Commissioning under progress

CW Chlorination and SACW are

IDCT under Comissioning Commissioning under progress
Fire Water Pump House under Booster Pump System and Foam Pump
Fire Fighting service House are under commissioning
CW Chlorination and SACW are
CW Chlorination under Comissioning
Air conditioning Erection Pending
System(BOP)

11/06/2020 OR#1 42
 3. STATION PERFORMANCE ANALYSIS
UPS AVALABILITY
LOCATION CAPACITY BATTERY REMARK

STATION DCS UNIT#1 2X150 KVA From Main DC bank Working normal

STATION DCS UNIT#2 2X150 KVA From Main DC bank Working normal

2 X 10KVA SMF Battery Commissioned, Battery

CHP bank not connected.
Commissioned but not in
AHP 2 X 10KVA SMF Battery service (used only for
Ethernet Switch)
Commissioned but not in
DM Plant 2 X 10 KVA SMF Battery service (used only for
Ethernet Switch)
Commissioned but not in
Compressors (BTG) 2 X 10 KVA SMF Battery service (used only for
Ethernet Switch)

2 X 10 KVA SMF Battery Commissioned but not in

IDCT
service

2 X 10 KVA SMF Battery Commissioned but not in

Fire Fighting
service

H2 Plant 2 X 10 KVA SMF Battery Not erected

11/06/2020 OR#1 43
 Concern
Description

Condenser CW tube fouling, affecting heat rate of the turbine.

Poor effectiveness of Cooling tower & Frequent failure of CT fans. (Structure stability) .

High slagging tendency resulting into clinker formation.

Non availability of critical spares particularly in AHP.

ESP hopper Ash Evacuation demonstration by EPC.

Mill Rejection system yet to be proven.

LRSB Pressure setting

Inlet & outlet Isolation valves are passing on DMCW-PHE coolers, ACW A,B & C

Boiler different elevation, the  furnace cladding skin temperature are on higher side due to lack of insulation.

When ever the safety valve floats the entire insulation get dislodged from the pipes

Cable Trench water ingress.

44
11/06/2020 OR#1
 Concern
Description

Electric Lab, Mechanical Workshop not available.

Auto Coal sampler.(3A/3B)-Pending

Emergency Light to be commissioned in Track Hopper and Tunnels, Switch Gear Room, stair case

Data concentrator is not properly through , many relays are not communicating properly.

Recommended relay setting to be implemented for BOP area to avoid spurious tripping of transformer &
board.

Auto bus change over is not successful in 3.3 KV and LT board.

Ventilation in track hopper and tunnel.

Conveyor system water spray system.

45
11/06/2020 OR#1
 CHEMISTRY
DEVIATION IN WATER CHEMISTRY
A) RAW- CLARIFIED water Parameters

Raw Water Limit DM Clarifier Outlet

Parameters UOM
Min Max Average Min Max Average

pH at 25 degree   8.30 8.65 8.42 7.0-8.2 7.00 7.82 7.45

Specific 750 843 814 763 862 831

us/cm
Conductivity
Turbidity NTU 3.03 5.05 4.14 <2.0 2.86 4.94 3.59

Total Hardness as 188 210 204 188 210 204

mg/L
CaCO3

Chloride as CaCo3 mg/L 100 114 108 67 102 116 110

Total Dissolved 487 548 529 495 560 539

mg/L
Solids

Silica as SiO2 mg/L 17 21 19 20 20 20

Alkalinity as 122 150 134 120 112 138 121

mg/L
CaCo3
Free Residual 0.2-0.5 0.2 1.0 0.5
mg/L
Chlorine
5 January 2015 OR#47 46
 CHEMISTRY
DEVIATION IN WATER CHEMISTRY
COOLING WATER PARAMETERS

CW Clarifier Outlet CW Forebay

Parameters UOM Limit
Min Max Average Limit Min Max Average

pH at 25 degree   8.0 7.45 8.14 7.68 7.5 – 8.0 7.72 7.98 7.90
Specific 350 2500
us/cm 771 859 830 3140 3670 3394
Conductivity
Turbidity NTU < 5.0 2.65 5.30 3.19 < 10 10.2 19.3 15
Total Hardness as 186 900
mg/L 190 210 204 846 1020 916
CaCO3
Chloride as Clˉ mg/L 75 102 120 113 < 600 472 568 513
Total Dissolved 231 1650
mg/L 501 834 549 2041 2385 2206
Solids
Alkalinity as 120
mg/L 112 136 123 100 ± 20 32 58 47
CaCo3
Cycle Of
  5.0 4.10 5.01 4.49
Concentration
Free Residual
mg/L 0.6 1.0 0.9 0.2- 0.5 0.1 0.2 0.2
Chlorine
Langelier Index   0.5 +0.18 +0.69 +0.54

Silica as CaCo3
5 January 2015 Mg/L 16.58 17 21
OR#47 18 < 100 68 90 7847
 CHEMISTRY
DEVIATION IN WATER CHEMISTRY
B) DM WATER

Parameters UOM Range Min Max Remarks

pH at 25 degree   6.8 - 7.3 6.56 6.80

Silica as SiO2 ug/L 10 <10 <10
Conductivity us/cm 0.5 0.10 0.15

DM Water (m³)

DM Water Production Consumption Internal Closing Stock

Opening Stock consumption

2709 39357 36591 2460 3015

5 January 2015 OR#47 48

 CHEMISTRY
WATER CHEMISTRY PARAMETERS
Unit-1 Unit-2
System Parameter Limits
Max Min Avg Max Min Avg
CC (us/cm) < 0.2 0.20 0.11 0.15 0.18 0.09 0.11

Condensate 9.31 8.88 9.12 9.30 8.95 9.11

pH 8.8 - 9.3
Water
DO (ppb) <30 ppb Off line instrument not available

CC (us/cm) < 0.3 0.35 0.20 0.21 0.29 0.11 0.16

Feed Water pH 8.8 - 9.3 9.37 8.91 9.16 9.29 8.99 9.14
Off line instrument not available
DO (ppb) < 7 ppb
S.Conductivity 15 5.41 8.87 19.78 4.66 8.46
< 50
(us/cm)

Boiler Water pH 9.0 - 9.5 9.44 9.06 9.25 9.41 9.04 9.23

SILICA (ppb) < 100 58 40 44 800 41 91.46

pH 8.8 - 9.3 9.34 8.95 9.18 9.30 9.01 9.17

Main Steam
SILICA (ppb) <20 ppb 12 10 10 48 10 12.60

CC(us/cm) < 0.2 0.18 0.09 0.12 0.15 0.10 0.13

CPU (O/L) pH 6.68 6.06 6.32 6.44 6.09 6.21

Silica(ppb) < 15 10 6.0 8.23 10 10 10

5 January 2015 OR#4.7 49

 CHEMISTRY
WATER CHEMISTRY PARAMETERS (ONLINE-Average)

System Parameter Limits Unit-1 Unit-2

CC (µs/cm) < 0.2 0.15 0.11

Condensate
Water S.Conductivity(µs/cm) <6 5.84 5.65
DO (ppb) <30 ppb NW NW
CC (µs/cm) < 0.3 0.21 0.16
pH 8.8 - 9.3 9.02 8.82
Feed Water
DO (ppb) < 7 ppb NW NW
S.Conductivity(µs/cm) <6 5.95 5.64
S.Conductivity(µs/cm) < 50 10.12 12.16
Boiler Water pH 9.0 - 9.5 9.46 9.35
SILICA (ppb) < 250 NW NW

CC (µs/cm) < 0.2 0.15 0.14

SILICA (ppb) <20 ppb NA NA
Main Steam

Sodium (ppb) < 10 ppb NW NW

5 January 2015 OR#47 50
 CHEMISTRY
CHEMICAL STOCK AS ON
26/08/17

Consumption Present Stock Inventory

Chemical Remarks
(MT) (MT) Duration (Days)
Hydrochloric acid (HCL ) 101.833 7.03 2.0
Caustic Lye (NaOH) 36.055 7.795 6.5
Tri Sodium Phosphate (TSP) 0.009 1.0 333
Hydrazine hydrate(N2H4H2O) 0.338 1.30 65
Liquor ammonia(NH3H2O) 0.575 6.00 55
Potassium hydroxide(KOH) NIL NIL NIL
Alum 35.247 5.50 5.5
Lime 3.875 8.00 88
NaOH Flakes NIL NIL NIL
Sulphuric Acid 0.17 0.064 8

5 January 2015 OR#47 51

 5. CHP
 Bullet Points

S.No Description UOM Best parameters July,17 Aug,17 Remarks

1 Opening Stock MT 3,55,136 3,47,347 ↑

Total Coal received MT 4,17,516 4,95,914 ↑

2 Total Coal
Conveyed MT 4,24,404 5,29,253 ↑
from(BCN-3A & 3B)

3 Closing Stock  MT 3,47,447 3,55,639 ↑

4 Belt Utilization % 34.65 39 *** ↑

5 SPC (Bunkering) KWH/Ton 2.6 2.51

*** Low Utilization factor due to :-

1. Con-1A , VSF-1 Not available since 15-06-2017 due to drum problem(MBE).
2. Con-5A/5B and Con-7A/7B Over load problem.
3. Paddle Feeder feeding Restricted.
11/06/2020 OR#1 52
 5. CHP
 CONVEYOR BELT REPLACEMENT (For 2017)

Qty. Replaced Actual Thickness Original

Sl. No. Belt No. Reason Replaced On when belt replaced Thickness
(m) (mm) (mm)

1. NOV-16 NIL

2. DEC-16 NIL

3. JAN-17 NIL

4. ILMS-1 BELT CUT 19-02-17 7 11 14

5. MAR-17 NIL

6. CON-3A BELT JOINT WEEK 05-04-2017 19M 15 16

7. MAY-17 NIL

8. JUNE-17 NIL

9. JULY-17 NIL

11/06/2020 OR#1 53
 5. CHP

 CONVEYOR PROTECTIONS BYPASSED: NIL

Equipment Total Installed Available Not Available Remarks

  CHP CHP CHP  
Pull chord Switch 5A-2
326/328 326 2
(Not in service due
to PCS installed but
cable N/A )
Belt Sway switch 9B-4 (Not installed)
209/216 209 7
BF4-1,2A-1,1A-1
(lever N/A)
ZSS Con-1A,Cr-A/B ,Cr-
5/20 5 15
C/D are Available &
Remaining are Not
In Service

11/06/2020 OR#1 54
 5. CHP
CONVEYOR PROTECTION
 CONVEYOR PROTECTIONS BYPASSED: NIL
Protections Local PLC Remarks

PULL CORD OK OK Con-9B not in service through PLC

BELT SWAY OK OK BF-3,Con-8A,9B BSS Cable N/A
ZSS OK OK
METAL DETECTOR OK OK
SUSPENDED MAGNETS OK OK
IN LINE MAGNETIC ILMS-3 N/A pressure Pulley damage
OK OK
SEPARATORS

EQUIPMENT AVALABILITY
Equipment Availability N/A Since Status
Paddle feeder A - A
Crusher A, Screen A A - A
Crusher B, Screen B A - A
Crusher C, Screen C A - A
Crusher D, Screen D A VSF-1 N/A 15-06-17 A
Stacker/Reclaimer 1 A - Initial Trial Taken
Stacker/Reclaimer 2 A - Under Erection
A - 10,11,12,13,14B
All Conveyors Under Erection
D-80NEW(10-08-17)

D-155 (20-05-2017)
Bull dozers A D-120(24-08-17)
D-120NEW(14-8-17)

11/06/2020 OR#1 55
 5. CHP
INVENTORY
BELT STOCK :-

Type of Capacity
Location Installed Longest Current
Belt Type (TPH) Quantity belt in the No. of WIDTH Idle Stock at
(m) Group Ply (mm) Stock Store (m)

I NN1600/4 1400 1&3 4376 1380 4 1400 - nil

II NN800/4 1400 RBF-1&2 60 30 4 1800 - nil

III NN630/4 770 BF-1TO4 78 19.5 4 1600 - nil

IV NN800/4 1400 14 1733 870 4 1400 - nil

NN630/4 1400 2,4,5,6,7,8,9, 7368.28 798.5 4 - nil

V 10,11,12,13 1400

11/06/2020 OR#1 56
 5. CHP
IDLER STOCK:-

Type of For Belt Diameter Installed Current

Idler Name Width (mm) Location Quantity Stock at
Idler (mm) Store
10° Transition 1400 152.4 Con-1 to 14 64 Nil
1 Idler
20° Transition 152.4 Con-1 to 14 64 NIL
2 Idler 1400
3 S.A Carrying idler 1400 152.4 Con-1 to 14 448 150
4 Impact 35° 1400 190 Con-2 to 14 372 90
5 Carrying 35° 1400 152.4 Con-1 to 14 5392 Nil
S.S Carrying 35° 152.4 Con-1 & 3 20 Nil
6 idler 1400
7 F.S.A Return idler 1400 152.4 Con-2 to 13 246 Nil
Self cleaning 152.4 Con-1 to 14 28 Nil
8 R . Idler (Flat) 1400
9 Flat Return Idler 1400 152.4 Con-1 to 14 1207 75
V-Type Return 152.4 1A/B,14A/B 764 80
10 Idler 1400
11 Deflector Roller 1400 219 Con-1 to 14 28 Nil
10° Transition 152.4 BF-1 to 4 8 Nil
12 Idler 1600
20° Impact 152.4 BF-1 to 4 8 Nil
13 Transition Idler 1600
14 S.A Carrying idler 1600 152.4 BF-1 to 4 4 Nil
15 Impact 35° 1600 190 BF-1 to 4 42 Nil
16 F.S.A Return idler 1600 152.4 BF-1 to 4 4 Nil
Self cleaning 152.4 BF-1 to 4 4 Nil
17 R . Idler (Flat) 1600
 5. CHP
IDLER STOCK:-

Type of For Belt Diameter Installed Current

Idler Name Width (mm) Location Quantity Stock at
Idler (mm) Store
18 Deflector Roller 1600 219 BF-1 to 4 4 Nil
10° Transition 152.4 RBF-1&2 4 Nil
19 Idler 1800
20° Transition 152.4 RBF-1&2 2 Nil
20 Idler 1800
20° Impact 152.4 RBF-1&2 2 Nil
21 Transition Idler 1800
22 S.A Carrying idler 1800 152.4 RBF-1&2 2 Nil
23 Impact 35° 1800 190 RBF-1&2 22 Nil
24 Carrying 35° 1800 152.4 RBF-1&2 6 Nil
25 F.S.A Return idler 1800 152.4 RBF-1&2 2 Nil
Self cleaning 152.4 RBF-1&2 2 Nil
26 R . Idler (Flat) 1800
27 Flat Return Idler 1800 152.4 RBF-1&2 2 5
28 Deflector Roller 1800 219 RBF-1&2 2 Nil
 6. STATUTORY / REGULATORY
UPDATES

Sl. No. PARTICULARS STAT. AUTHORITY FREQUENCY VALIDITY/ STATUS

1 Fire tender fitness RTO Yearly December 13, 2017
The Oriental
2 Fire tender Insurance Yearly August 28, 2017
Insurance
April 06, 2017 (sent for
3 Portable gas detector Factories Act 1948 Half yearly
calibration)
Due in Sept 2017 (in final
4 Employee health checkup Factories Act 1948 Yearly
stage)
5 Lifting Tools & Tackles Factories Act 1948 Yearly May 2018 & Jan 2018
TS Boiler Inspection
6 Boiler #1 Licence Form VI Yearly once March 02, 2018
Dept.
TS Boiler Inspection
7 Boiler #2 Licence Form VI Yearly once August, 2018
Dept.
8 Pressure Vessels examination Factories Act 1948 Half-yearly Awaited from SCCL
9 Ambient Air Monitoring Third Party Monthly Yet to be Installed by SCCL
Submission of Environmental
10 SPCB - TS Yearly September 2017
statement
11 Environmental Audit SPCB - TS Yearly April 2017
Conducted in March
12 External Safety Audit Factories Act 1948 Yearly
2017

11/06/2020 OR#1 59
 Thank You
11/06/2020 OR#1 60
 2. STATION PERFORMANCE
APC Deviation

APC DEVIATION FOR MONTH

UNIT# UNIT#2 STATION
S.NO. PARAMETERS MOU 1 Reason Unit#1 Reason Unit#2
443.08 435.73 878.81
1 GROSS GENERATION MU    
5.75 5.75 5.75
2 TARGET APC %    
25.20 25.91 51.12    
3 APC MU
5.69 5.95 5.82    
4 %

0.101 0.715 0.82

5 MU MDBFP was in operation during TDBFPA
MDBFP CONSUMPTION   Bearing failure a & main control valve
fluctuation rectification work,
0.02 0.16 0.09
6 %
0.00 0.12 0.12 During Unit shut down auxiliary
7 SHUTDOWN APC MU   consumption
0.00 0.03 0.01
8 %
25.10 25.08 50.19    
9 MU
NET APC
5.67 5.76 5.71
10 %    

11/06/2020 OR#1 61
 STATION PERFORMANCE
Oil Consumption Detail

FD fan 1 A blade pitch; 5.86; 7%

Unit Tripping & start

FD fan 1 A blade pitch

Unit Tripping & start; 77.12; 93%

11/06/2020 OR#1 62
 3. STATION PERFORMANCE ANALYSIS
Reason wise BTL Financial Year 2017-18

Reason Wise Boiler Tube Leakage In FY-2017-18

  Shop Joint Failure Field Joint Failure Flue Gas erosion Blocking/Fish mouth

U#1 0 1 2 2(Right angle Found in

Platen Super Heater)
U#2 1 3    

11/06/2020 65
OR#1
 6. STATUTORY / REGULATORY
UPDATES

Sl. No. PARTICULARS STAT. AUTHORITY FREQUENCY VALIDITY/ STATUS

1 Schedule maintenance of All Fire BIS - 2190 Monthly As per PM plan

extinguishers

 DCP,FOAM,WATER -  DCP,FOAM,WATER - July

Once in three years 2018
2 Fire extinguishers Hydro test PESO/ Dy. CCOE, Hyd.  CO2 - Once in five  CO2 - July 2020
years

3 Fire tender fitness RTO Yearly December 13, 2017

4 Fire tender Road Tax RTO Yearly March 31, 2018
The Oriental
5 Fire tender Insurance Yearly August 28, 2017
Insurance
6 Ambulance Insurance National Insurance Yearly July 28, 2018

7 Portable gas detector Factories Act 1948 Half yearly April 06, 2017 (sent for
calibration)

Smoke / Heat detectors / Alarms BIS- 2189, 3034,

8 Half yearly Yet to be commissioned
Testing NFPA 72 / Internal

9 Employee health checkup Factories Act 1948 Yearly Due in Sept 2017 (in final
stage)
Conducting of Mock drill in plant
10
11/06/2020
Factories Act 1948
OR#1
Six months Conducted on 31.08.17
66
area
 6. STATUTORY / REGULATORY
UPDATES

STAT.
Sl. No. PARTICULARS AUTHORITY FREQUENCY VALIDITY/ STATUS

11 Register of accidents Factories Act 1948 Incident based Register is in place 

12 Storage of Petroleum Class - C PESO/ Dy. CCOE, Hyd. Once in Ten years December 31, 2024

Decibel meter yet to be

13 Noise Level Monitoring Factories Act 1948 Monthly
procured by SCCL

14 Safety Committee Meeting Factories Act 1948 Monthly Done on 04.08.17

Register containing particulars of

15 monitoring of working Factories Act 1948 Quarterly Ongoing 
environment

16 Lifting Tools & Tackles Factories Act 1948 Yearly May 2018 & Jan 2018

17 Factories Drawing/ Plan Approval Director of Factories One Time Approved in February 2017

18 Factory License Director of Factories One Time Issued in March 2017

TS Boiler Inspection
19 Boiler #1 Licence Form VI Yearly once March 02, 2018
Dept.
2011/06/2020
Boiler #2 Licence Form VI TS Boiler Inspection Yearly once August, 2018 67
OR#1
Dept.
 6. STATUTORY / REGULATORY
UPDATES

STAT.
Sl. No. PARTICULARS AUTHORITY FREQUENCY VALIDITY/ STATUS

21 Pressure Vessels examination Factories Act 1948 Half-yearly Awaited from SCCL

Periodic Testing of Chlorine Tonner

22 (38 nos) PESO Two Years August 23, 2018

License of Hydrogen gas cylinders

23 storage room CCOE Yearly Awaited from SCCL

Factories Dept. / Third

24 Stability Certificate for Buildings Party Once in Five years Awaited from SCCL

Factories Act 1948/

25 Industrial all risk policy schedule Yearly In place
Insurance

26 Drinking water analysis BIS - 3025 & CPCB Yearly Awaited from SCCL

27 Ambient Air Monitoring Third Party Monthly Yet to be Installed by SCCL

28 Water Sample Analysis – CMB BIS - 3025 & CPCB Monthly Under construction
Water Sample Analysis – CW Blow
29 BIS - 3025 & CPCB Weekly Ongoing 
Down
Sludge Sample Analysis- Storage
30 SPCB Under construction
sludge
11/06/2020 OR#1 68
 6. STATUTORY / REGULATORY
UPDATES

Sl. No. PARTICULARS STAT. FREQUENCY VALIDITY/ STATUS

AUTHORITY

31 Compliance Report of water SPCB, TS Quarterly To be provided by SCCL

32 Compliance Report of Air SPCB, TS Quarterly To be provided by SCCL

Compliance CCA Report for the

33 storage, handling and transport of SPCB, TS Once in Five years Valid up to April 2022
Hazardous waste / chemicals

Submission of Environmental
34 statement SPCB - TS Yearly September 2017

35 Environmental Audit SPCB - TS Yearly April 2017

36 Consent for Operation (Air and SPCB - TS Once in Five years April 2022
Water Act) & HWA

Conducted in March
37 External Safety Audit Factories Act 1948 Yearly
2017
11/06/2020 OR#1 69